True Treadmills Diagnostics
Posted: February 22nd, 2022, 10:00 am
TRUE FITNESS Treadmill 2011 model
Diagnostic mode
2 WINDOW DISPLAY
Press CLEAR ENTRY until the screen blanks then press hold ENTER. [ or Hold speed Up Key while inserting safety key ]
A. Input 10101 (Basic Mode) B. Input 20173(Service Mode)
11” WINDOW DISPLAY
Press CLEAR ENTRY until the screen blanks then press and hold ENTER:
A. press 10101 (Manager Mode)
B. Press 20173 (Service Mode)
C. Press 48362 (Configuration Mode)
15” Touch Screen
The Maintenance Mode is designed to help the tech determine certain faults in the upper control boards and feedback from the brake system.
Press and hold the top left corner of screen until the True emblem will begin to flash after 4 seconds.
Press and hold Manual Workout Button to reveal list of options
1.Configure (Displays the current model setup)
2.Calibration (Speed / Elevation Calibration)
3.Diagnostics (Check hours, distance, error log)
4.Production Tests (Test various functions)
5.Utilities (Install software, TV tuner setup, touch screen setup)
Error codes
E1 STALL
The elevation up and down LED’s on the lower boards of all True Fitness Treadmills are used for elevation troubleshooting.
These LED’s illuminate when a command is received from the upper control board to raise or lower the incline. If there is no illumination of incline LEDs, check data cable for continuity.
If there is illumination of a incline LED and no motor movement listen to the motor.
If there is a humming noise coming from the motor and no movement, replace the motor.
If the LED’s illuminate and there is no motor humming, check the 3 amp slow blow fuse on the lower board for continuity.
This fuse protects the 18 volt system that controls the elevation relays. If there is no continuity, replace the fuse. If the fuse blows a second time replace the lower board.
E1 STALL/ E1 RANGE
# If the value at zero or -3% incline is outside the acceptable range (see pg. 11) of the correct digital value, the machine will give an elevation error (either E1 Stall or E1 Range depending on model).
# On units with an external limit switch, the digital value can be adjusted by disconnecting the elevation motor from the incline rack and manually turning the linear shaft of the incline motor until it reads the correct digital value at 0% or -3%.
# On treadmills with internal limit switches in the incline motor the ideal zero will be set when the internal switch activates.
# A value reading 255 or 0 often indicates over travel of the potentiometer or a wire disconnect between the potentiometer and the upper control panel.
E2 CAL
This error will occur if the upper and the lower boards lose their calibration parameters. See calibration procedure(pg 47)
Note: May be caused by speed fluctuation.
#Check for high friction by performing a Push-off test.(pg 35)
#To perform this test raise the elevation to the highest level and remove safety key.
#While standing on the belt push away from the handle bar.
#If there is high friction between the belt and deck it will be difficult to push away.
#Units with low friction will be easy to push away.
#High friction can lead to excess amp draw on the motor. The motor may overcompensate causing an error code. If this is not addressed, it will lead to motor controller failure.
#Replace running belt and deck as needed
#Check the line voltage for fluctuations. This can cause erratic speeds.
E5 SENSOR
E5 Sensor Error (without belt movement):
If the upper control board does not see adequate feedback from the speed sensor when the belt is being commanded to move this error will occur.
This error can occur for different reasons which we have listed below.
First, if there is a break in the main data cable, the speed feedback information will not make it back to the upper board.
Check to see if there is speed feedback in the upper board while in calibration.
Next check continuity on the data cable to verify there is no break in the connection.
If the upper board command signal is not being received at the lower board there will be no belt movement.
E5 SENSOR
E5 Sensor (without belt movement.)
AC DRIVES:
The AC Drive on the CS Series Treadmills has a unique error reporting system that helps in the diagnostic troubleshooting of system faults. To read errors- count the blink code that flashes on the lower board LED’s 1, 2 and 3.
Note: This blink code will only display as long as the lower board has not been reset. There currently is no drive fault error reporting on the upper board.
DC DRIVES:
Check to see if the PWM light is lit on the lower board. If this LED is illuminated there should be belt movement and there should be AC or DC voltage being sent to the motor depending on the type of drive system in question.
Measure the output pins (to the drive motor) on the lower board. When checking output voltage the motor or load must be connected to the motor controller when measuring this voltage.
E5 SENSOR
E5 Sensor (Belt moves for 5-10 seconds.)
No Speed Sensor Feedback
First check to see if the RPM light flashes on the lower board (and the Smart Board-if applicable) when moving the drive motor and running belt by hand.
If there is no LED flashing on either board proceed to the following steps. If the LED flashes perform a continuity check on the data cable. If the cable checks good, replace the upper board.
All current production models have a RPM LED on the lower boards.
A misaligned or damaged speed sensor can cause an E5 Sensor error after pressing start and no sensor feedback is detected after 10 seconds.
E5 SENSOR
1. An optical sensor is used on our newer AC drive systems for the TCS Series (Reads off wheel on drive motor)
On the optical sensor, measure DC volts between pins 2 and 3 of the speed sensor plug while plugged into the lower board. There should be a reading of 5VDC(on) to below 1VDC(off). Readings of 1.90VDC or higher during the off cycle could cause the RPM LED to not cycle and will result in a speed error. If this speed sensor test is successful replace the lower board. If the speed sensor test fails replace the speed sensor.
Check to see if the speed LED flashes on the lower board when moving the belt by hand.
If there is a flashing speed LED on the lower board, enter calibration and check for speed feedback in the upper panel display. Check the data cables for continuity or try a known good 20 pin cable between the MCB and the Smart Board and the 10 pin console cable. If there is still no speed feedback in the upper panel, replace the upper panel.
Most common cause his high belt and deck friction. Perform amp draw test.
NO CONSOLE DISPLAY
A. ALL CONSOLES EXCEPT TOUCHSCREEN
Check the obvious! Make sure there is AC voltage available at the outlet, check the breaker on the unit to see if it is tripped, and look for any visible damage on the power cord and data cable.
Check the AC and the VCON (11VDC) LED on the lower board to see if they are illuminated; if these LEDs are not illuminated there will not be 11VDC available to the upper control board. Check the fuses on the lower board.
If the AC and VCON (11VDC) LEDs are lit and there is still no display look for damage on the data cable, and check for 11VDC on the data cable at the control board. Refer to the unit’s wiring diagram for the print out on the specific data cable being tested.
If there is 11VDC from the data cable at the display, the board should power up; if not, replace the control board.
B. TOUCHSCREEN ONLY
If console is a touchscreen, power comes from a 12 VDC power adapter in base of unit. Check for power LED on adapter. If on, check for 12 VDC at console connection
TOUCHSCREEN BUTTONS NOT RESPONDING
NEEDS SCREEN CALIBRATION:
1. Press and hold the upper left corner of HOME screen until the logo on HOME screen begins to flash on and off. Stop pressing left corner.
2. Then press and hold the MANUAL WORKOUT key in the bottom right corner of the HOME screen. The MAINTENANCE screen will appear at this point.
3. Press the UTILITES button.
4. Press the TOUCHSCREEN CALIBRATION button.
5. Follow the on screen instructions to CALIBRATE your display. Once all TARGETS have been pressed, press the blue HOME button to complete TOUCHSCREEN CALIBRATION.
Touch Screen Will Not Function When buttons pressed
PERFORM CALIBRATION OF TOUCH SCREEN
1. Press hold: UP grade and MINUS speed
2. After 10-15 seconds touch screen calibration will display.
3. Software version:
If software version below (<)1.8 Press each of the 3 “targets” as they appear on the screen.
If software version above or equal to (>=) 1.8 Press each of the 9 “targets” as they appear on the screen.
4. When step 3 is complete press “HOME”.
5. Check for function of the touch screen.
6. If touch screen continues to not function replace console.
AC Amp Draw Test (All Models)
1. Place an AC clamp meter around the black incoming power lead.
2. Let the treadmill run at 2.5 mph and 5.0 mph.
3. At 2.5 mph the treadmill should be drawing 0.5 -1.5 AMPS AC. (No Load)
At 5.0 mph the treadmill should be drawing 1.5 -2.5 AMPS AC. (No Load)
4. Walk on the treadmill at 2.5 mph and 5.0 mph.
5. At 2.5 mph the treadmill should be drawing 2.0-4.0 AMPS AC. (Load)
At 5.0 mph the treadmill should be drawing 3.0-6.0 AMPS AC.(Load)
6. Higher than normal amp draws without load may signal that running belt tension is too tight or that there is a problem in the drive motor or controller.
7. If amp draw is higher than expected only under a load, lubricate the running deck and running belt. If amp draw is still high, replace the running deck and running belt. Higher than normal ampdraws signal running belt and running deck friction which may require lubrication or replacement.
Speed Sensor Test (TPS Series/ Z Series)
This test will expose the technician to a potential pinch hazard. Exercise caution when performing test.
1. Remove the motor cover and verify that the speed sensor is between 1/8” to 1/4” away from the roller pulley (TPS Series, Z series).
2. Turn the flywheel on motor so that there is belt movement. Verify that the speed LED blinks on the lower board when there is movement at the speed sensor.
3. If the Speed LED does not blink, replace the speed sensor.
Optical Sensor Test (TCS Series)
On the optical sensor, measure DC volts between pins 2 and
3 of the speed sensor plug while plugged into the lower board. There should be a reading of 5VDC(on) to below 1VDC(off). Readings of 1.90VDC or higher during the off cycle could cause the RPM LED to not cycle and will result in a speed error.
If this speed sensor test is successful replace the lower board. If the speed sensor test fails replace the speed sensor.
Diagnostic mode
2 WINDOW DISPLAY
Press CLEAR ENTRY until the screen blanks then press hold ENTER. [ or Hold speed Up Key while inserting safety key ]
A. Input 10101 (Basic Mode) B. Input 20173(Service Mode)
11” WINDOW DISPLAY
Press CLEAR ENTRY until the screen blanks then press and hold ENTER:
A. press 10101 (Manager Mode)
B. Press 20173 (Service Mode)
C. Press 48362 (Configuration Mode)
15” Touch Screen
The Maintenance Mode is designed to help the tech determine certain faults in the upper control boards and feedback from the brake system.
Press and hold the top left corner of screen until the True emblem will begin to flash after 4 seconds.
Press and hold Manual Workout Button to reveal list of options
1.Configure (Displays the current model setup)
2.Calibration (Speed / Elevation Calibration)
3.Diagnostics (Check hours, distance, error log)
4.Production Tests (Test various functions)
5.Utilities (Install software, TV tuner setup, touch screen setup)
Error codes
E1 STALL
The elevation up and down LED’s on the lower boards of all True Fitness Treadmills are used for elevation troubleshooting.
These LED’s illuminate when a command is received from the upper control board to raise or lower the incline. If there is no illumination of incline LEDs, check data cable for continuity.
If there is illumination of a incline LED and no motor movement listen to the motor.
If there is a humming noise coming from the motor and no movement, replace the motor.
If the LED’s illuminate and there is no motor humming, check the 3 amp slow blow fuse on the lower board for continuity.
This fuse protects the 18 volt system that controls the elevation relays. If there is no continuity, replace the fuse. If the fuse blows a second time replace the lower board.
E1 STALL/ E1 RANGE
# If the value at zero or -3% incline is outside the acceptable range (see pg. 11) of the correct digital value, the machine will give an elevation error (either E1 Stall or E1 Range depending on model).
# On units with an external limit switch, the digital value can be adjusted by disconnecting the elevation motor from the incline rack and manually turning the linear shaft of the incline motor until it reads the correct digital value at 0% or -3%.
# On treadmills with internal limit switches in the incline motor the ideal zero will be set when the internal switch activates.
# A value reading 255 or 0 often indicates over travel of the potentiometer or a wire disconnect between the potentiometer and the upper control panel.
E2 CAL
This error will occur if the upper and the lower boards lose their calibration parameters. See calibration procedure(pg 47)
Note: May be caused by speed fluctuation.
#Check for high friction by performing a Push-off test.(pg 35)
#To perform this test raise the elevation to the highest level and remove safety key.
#While standing on the belt push away from the handle bar.
#If there is high friction between the belt and deck it will be difficult to push away.
#Units with low friction will be easy to push away.
#High friction can lead to excess amp draw on the motor. The motor may overcompensate causing an error code. If this is not addressed, it will lead to motor controller failure.
#Replace running belt and deck as needed
#Check the line voltage for fluctuations. This can cause erratic speeds.
E5 SENSOR
E5 Sensor Error (without belt movement):
If the upper control board does not see adequate feedback from the speed sensor when the belt is being commanded to move this error will occur.
This error can occur for different reasons which we have listed below.
First, if there is a break in the main data cable, the speed feedback information will not make it back to the upper board.
Check to see if there is speed feedback in the upper board while in calibration.
Next check continuity on the data cable to verify there is no break in the connection.
If the upper board command signal is not being received at the lower board there will be no belt movement.
E5 SENSOR
E5 Sensor (without belt movement.)
AC DRIVES:
The AC Drive on the CS Series Treadmills has a unique error reporting system that helps in the diagnostic troubleshooting of system faults. To read errors- count the blink code that flashes on the lower board LED’s 1, 2 and 3.
Note: This blink code will only display as long as the lower board has not been reset. There currently is no drive fault error reporting on the upper board.
DC DRIVES:
Check to see if the PWM light is lit on the lower board. If this LED is illuminated there should be belt movement and there should be AC or DC voltage being sent to the motor depending on the type of drive system in question.
Measure the output pins (to the drive motor) on the lower board. When checking output voltage the motor or load must be connected to the motor controller when measuring this voltage.
E5 SENSOR
E5 Sensor (Belt moves for 5-10 seconds.)
No Speed Sensor Feedback
First check to see if the RPM light flashes on the lower board (and the Smart Board-if applicable) when moving the drive motor and running belt by hand.
If there is no LED flashing on either board proceed to the following steps. If the LED flashes perform a continuity check on the data cable. If the cable checks good, replace the upper board.
All current production models have a RPM LED on the lower boards.
A misaligned or damaged speed sensor can cause an E5 Sensor error after pressing start and no sensor feedback is detected after 10 seconds.
E5 SENSOR
1. An optical sensor is used on our newer AC drive systems for the TCS Series (Reads off wheel on drive motor)
On the optical sensor, measure DC volts between pins 2 and 3 of the speed sensor plug while plugged into the lower board. There should be a reading of 5VDC(on) to below 1VDC(off). Readings of 1.90VDC or higher during the off cycle could cause the RPM LED to not cycle and will result in a speed error. If this speed sensor test is successful replace the lower board. If the speed sensor test fails replace the speed sensor.
Check to see if the speed LED flashes on the lower board when moving the belt by hand.
If there is a flashing speed LED on the lower board, enter calibration and check for speed feedback in the upper panel display. Check the data cables for continuity or try a known good 20 pin cable between the MCB and the Smart Board and the 10 pin console cable. If there is still no speed feedback in the upper panel, replace the upper panel.
Most common cause his high belt and deck friction. Perform amp draw test.
NO CONSOLE DISPLAY
A. ALL CONSOLES EXCEPT TOUCHSCREEN
Check the obvious! Make sure there is AC voltage available at the outlet, check the breaker on the unit to see if it is tripped, and look for any visible damage on the power cord and data cable.
Check the AC and the VCON (11VDC) LED on the lower board to see if they are illuminated; if these LEDs are not illuminated there will not be 11VDC available to the upper control board. Check the fuses on the lower board.
If the AC and VCON (11VDC) LEDs are lit and there is still no display look for damage on the data cable, and check for 11VDC on the data cable at the control board. Refer to the unit’s wiring diagram for the print out on the specific data cable being tested.
If there is 11VDC from the data cable at the display, the board should power up; if not, replace the control board.
B. TOUCHSCREEN ONLY
If console is a touchscreen, power comes from a 12 VDC power adapter in base of unit. Check for power LED on adapter. If on, check for 12 VDC at console connection
TOUCHSCREEN BUTTONS NOT RESPONDING
NEEDS SCREEN CALIBRATION:
1. Press and hold the upper left corner of HOME screen until the logo on HOME screen begins to flash on and off. Stop pressing left corner.
2. Then press and hold the MANUAL WORKOUT key in the bottom right corner of the HOME screen. The MAINTENANCE screen will appear at this point.
3. Press the UTILITES button.
4. Press the TOUCHSCREEN CALIBRATION button.
5. Follow the on screen instructions to CALIBRATE your display. Once all TARGETS have been pressed, press the blue HOME button to complete TOUCHSCREEN CALIBRATION.
Touch Screen Will Not Function When buttons pressed
PERFORM CALIBRATION OF TOUCH SCREEN
1. Press hold: UP grade and MINUS speed
2. After 10-15 seconds touch screen calibration will display.
3. Software version:
If software version below (<)1.8 Press each of the 3 “targets” as they appear on the screen.
If software version above or equal to (>=) 1.8 Press each of the 9 “targets” as they appear on the screen.
4. When step 3 is complete press “HOME”.
5. Check for function of the touch screen.
6. If touch screen continues to not function replace console.
AC Amp Draw Test (All Models)
1. Place an AC clamp meter around the black incoming power lead.
2. Let the treadmill run at 2.5 mph and 5.0 mph.
3. At 2.5 mph the treadmill should be drawing 0.5 -1.5 AMPS AC. (No Load)
At 5.0 mph the treadmill should be drawing 1.5 -2.5 AMPS AC. (No Load)
4. Walk on the treadmill at 2.5 mph and 5.0 mph.
5. At 2.5 mph the treadmill should be drawing 2.0-4.0 AMPS AC. (Load)
At 5.0 mph the treadmill should be drawing 3.0-6.0 AMPS AC.(Load)
6. Higher than normal amp draws without load may signal that running belt tension is too tight or that there is a problem in the drive motor or controller.
7. If amp draw is higher than expected only under a load, lubricate the running deck and running belt. If amp draw is still high, replace the running deck and running belt. Higher than normal ampdraws signal running belt and running deck friction which may require lubrication or replacement.
Speed Sensor Test (TPS Series/ Z Series)
This test will expose the technician to a potential pinch hazard. Exercise caution when performing test.
1. Remove the motor cover and verify that the speed sensor is between 1/8” to 1/4” away from the roller pulley (TPS Series, Z series).
2. Turn the flywheel on motor so that there is belt movement. Verify that the speed LED blinks on the lower board when there is movement at the speed sensor.
3. If the Speed LED does not blink, replace the speed sensor.
Optical Sensor Test (TCS Series)
On the optical sensor, measure DC volts between pins 2 and
3 of the speed sensor plug while plugged into the lower board. There should be a reading of 5VDC(on) to below 1VDC(off). Readings of 1.90VDC or higher during the off cycle could cause the RPM LED to not cycle and will result in a speed error.
If this speed sensor test is successful replace the lower board. If the speed sensor test fails replace the speed sensor.